TENSION 12 V TO 800 V EFFICIENT POWERTRAIN SOLUTIONS

Transcription

1 TENSION 12 V TO 800 V EFFICIENT POWERTRAIN SOLUTIONS FISITA 2015 K. Küpper, T. Pels, M. Deiml, A. Angermaier, T. Bürger, A. Weinzerl, G. Teuschl AVL List GmbH Public

2 CHANGE OF BOUNDARIES POWERTRAIN ELECTRIFICATION Customer Demands Vehicle Technology Legislation Driving Experience TCO Electrification WLTP Engine Transmission Electrification Vehicle 30 Oktober

3 Function TENSION 12 V TO 800 V WHAT IS THE BEST VOLTAGE LEVEL? Rightsizing Standardization 48V 24V 12V 96V 400V 600V 800V Cost / Complexity 30 Oktober

4 Function TENSION 12 V TO 800 V WHAT IS THE BEST VOLTAGE LEVEL? 12V Cost / Complexity 30 Oktober

5 12 V IS HERE TO STAY Fleets will remain predominantly 12 V due to cost 12 V vehicles will have significant impact on fleet fuel consumption Innovation for 12 V vehicles is mandatory 30 Oktober

6 12 V POWER SUPPLY SYSTEM After stop/start, Intelligent Power Supply Systems will become standard Dual Batteries or pure Li-Ion batteries gaining Charge acceptance and discharge power Denso already sold > 1 Mio 12V Li-Ion batteries SW ALT ST Pb Load Li-Ion Load Source: 30 Oktober

7 12V WHAT CAN YOU DO ON POWERTRAIN SIDE? High Efficiency High Performance 1,6l TGDI, e-supercharger 104 kw/4000 rpm FE Target: 90 g/km CO 2 1,75l TGDI, e-supercharger 400Nm / 3500rpm 350HP / 6500rpm (148 kw/l) 30 Oktober

8 Function TENSION 12 V TO 800 V WHAT IS THE BEST VOLTAGE LEVEL? 48V Cost / Complexity 30 Oktober

9 WHY STOP AT 48V? Significant cost saving at attractive functionality max. voltage < 60 V NO protection against contact required kw generating kw motoring Several hybrid options P1, P2, P3, P4 Unified VDA-standard 30 Oktober

10 4 DRIVERS FOR 48 V Performance Emissions 48V CO 2 Electric System 30 Oktober

11 4 DRIVERS FOR 48 V CO2 48V CO 2 30 Oktober

12 CO 2 Emissions 48 V DRIVER: CO 2 IMPACT OF FUNCTIONALITY 100% 95% 90% 12 V 12 V 48 V 48 V 48 V New Basis CO2 Indirect Benefit 85% 80% Basis w/o STST STST+IPSS Regen Brake Regen Brake+Boost Pwtr. Engine Measures Measures enabled by 48V C-Segment, 4 cyl. TGDI, automatic transmission, NEDC 30 Oktober

13 48 V DRIVER: CO 2 IMPACT OF DRIVING CYCLES CO2 100% 98% 96% 94% 92% 90% 88% 86% NEDC WLTC China City* Basis w/ STST Regen Brake Regen Brake+Boost *STST inhibited in China City due to energy balance C-Segment, 4 cyl. TGDI, automatic transmission 30 Oktober

14 4 DRIVERS FOR 48 V Performance 48V CO2 30 Oktober

15 48 V DRIVER: PERFORMANCE Electric supercharger 48V 2.0L 4-cylinder 4V TGDI DVVT engine 450 HP 168 kw/l 500 Nm (31.9 bar BMEP) Bi-Turbo waste gate TC 30 Oktober

16 4 DRIVERS FOR 48 V Emissions Emissions Emissions 48V CO2 30 Oktober

17 NO x [mg] NO x [%] CO 2 [g] CO 2 [%] Velo city [km/ h] BSG [Nm] EMISSION & CO2 IMPROVEMENT Emissions Base Vehicle 48V BSG 13% Time [s] Oktober

18 NO x [mg] NO x [%] CO 2 [g] CO 2 [%] Velo city [km/ h] BSG [Nm] EMISSION & CO2 IMPROVEMENT Emissions Base Vehicle 48V BSG 13% Time [s] Oktober

19 NO x [mg] NO x [%] CO 2 [g] CO 2 [%] Velo city [km/ h] BSG [Nm] EMISSION & CO2 IMPROVEMENT Emissions Base Vehicle 48V BSG 13% 17% Time [s] Oktober

20 4 DRIVERS FOR 48 V Electric System Performance Emissions 48V CO2 Electric System 30 Oktober

21 48 V DRIVER: ELECTRIC POWER SUPPLY SYSTEM Electric System Three main trends, pushing 48 V Power Supply System (PSS) Fewer opportunities for electrical energy generation Increasing continuous power consumption More high power consumer 30 Oktober

22 48 V DRIVER: ELECTRIC PSS DESIGN REQUIRED! Electric System Vehicel Measurements Gen Power Gen Capacity DCDC Power Boosting Events 30 Oktober

23 48 V DRIVER: ELECTRIC PSS DESIGN REQUIRED! Electric System 100% 80% 60% Power and Energy Analysis Example: Luxury sedan w/ 48V electric supercharger City Hot city Race track Mountain 40% 20% 0% Generator Utilization P_act/Pmax_act Battery SOC Window Energy Share esc E_eSC/E_electr. E_eSC/E_electr. 30 Oktober

24 Vehicle Production in units Millions FORECAST GLOBAL XEV PRODUCTION Global xev Production Hybrid-Mild Hybrid-Full Fuel Cell Electric Source: IHS Q Market forecasts indicate strong growth of Mild Hybrid, driven by 48 V 30 Oktober

25 Vehicle Production in units Millions FORECAST GLOBAL MILD HYBRID PRODUCTION Global xev Production Hybrid-Mild Source: IHS Q Market forecasts indicate strong growth of Mild Hybrid, driven by 48 V 30 Oktober

26 Vehicle Production in units Millions FORECAST GLOBAL MILD HYBRID PRODUCTION Global xev Production Hybrid-Mild Source: IHS Q AVL predicts larger volumes of Mild Hybrids, driven by 48 V 30 Oktober

27 Function TENSION 12 V TO 800 V WHAT IS THE BEST VOLTAGE LEVEL? 400V Cost / Complexity 30 Oktober

28 HYBRID ROAD MAP 48 V Mild Hybrid CO 2 HV Full Hybrid today tomorrow 30 Oktober

29 TREND TOWARDS PLUG-IN HYBRIDS Legal CO 2 Requirements Legally, electric power is created with 0 g CO 2 / Credits Privileges for EV mode City access, privileges Electric Driving Experience 30 Oktober

30 HYBRID ROAD MAP 48 V Mild Hybrid CO 2 HV Full Hybrid HV Plug-In Hybrid Electric driving today tomorrow 30 Oktober

31 CLEAR TREND TO DEDICATED HYBRID TRANSMISSIONS (DHT) Most hybrid vehicle models use standard transmissions or slight modifications thereof (e.g. P2) Dedicated Hybrid Transmissions (DHT) will become standard DHT: Transmission not functional w/o e-machine Market Share 2014 Toyota Prius is dominating hybrid volumes already today with DHT Other Hybrids Dedicat ed Hybrid Transmi ssions Source: IHS Oktober

32 AVL FUTURE HYBRID NEXT GENERATION DHT Legislation -10% CO 2 compared to Powersplit -10% Piece Cost compared to Powersplit 30 Oktober

33 Function TENSION 12 V TO 800 V WHAT IS THE BEST VOLTAGE LEVEL? 800V Cost / Complexity 30 Oktober

34 HIGH POWER ELECTRIFICATION MOVING AHEAD Tesla S P 85D Audi R8 e-tron Lexus RX AMG Electric Drive BMW i8 More to come 30 Oktober

35 800V ADVANTAGES ON ELECTRIC SIDE Double power output compared to 400V at same current! Package & weight wiring Diameter and bending radius Saving of 10 kg in AVL demonstrator Package and weight power electronics Double power density Connectors: Cheaper ( paid by Amp ) 400V 90mm² 800V 35mm² 30 Oktober

36 CHARGING SPEED AS DECISIVE FACTOR 500km Range min 400V 9 km Range min 800V >20 km Range Tesla Supercharger: 270km/30min 30 Oktober

37 800V CHALLENGES Infrastructure DC charging standard available But no stations > 500 V AC-Charging possible (Onboard-Charger) But limited charging power (22kW) Auxiliaries Different voltage levels in vehicle may be required 800V, 400V, 48V, 12V Heater AC-compressor Power steering Source: 30 Oktober

38 800V CHALLENGES Power Electronics Availability: Components and technologies proven industry standard Automotive components test- and release effort, today limited choice Automotive systems development effort (also required for 400V high power) Efficiency Higher switching losses in IGBTs Options: Variable PWM frequency New semiconductor technology 30 Oktober

39 WORLD S FIRST 800V PASSENGER CAR: AVL COUP-E 800 Peak Power: 200 kw 30 Oktober

40 AVL S 800V BATTERY MODULAR POUCH CELL BATTERY WITH AVL BMS Battery Pack Details Configuration Installed pack energy Pack weight 180s1p 27,6 kwh 255 kg Highlights Self carrying modules Bus bar cooling system Cell tab clinching instead of Laser welding Serviceable E/E box 30 Oktober

41 AVL S 800V POWER ELECTRONICS PI450/850 POWER-INVERTER PLATFORM Technical Data U = 850V I = 300 A (430 A up to 10s) 1200 V IGBT Module Water/Glycol- Cooling Controller Software Field Oriented Control Software (FOC) Variable PWM Frequency up to 12kHz ASM/PSM drives 30 Oktober

42 Function EFFICIENT POWERTRAIN SOLUTIONS TENSION 12 V TO 800 V Rightsizing 400V 800V 800V High Performance 48V 400V Plug-in Dedicated Hybrid Transmissions 12V 48V Mainstream 12V Baseline Innovations Cost / Complexity 30 Oktober

43 THANK YOU